Fiberglassing a door panel.

by Pinch
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Ok, so I have been trying to figure a way to install the CDT-HD642 set I purchased a year ago in my 97 4Runner. What I came up with is to make a new set of door panels for the front doors. There is a stock location for the 6.5" and the tweet, but that 4" just wouldn't fit anywhere without making something new. I opted away from the kickpanel pod because there are computers for the car there (on at least the passenger side), and I am afraid the magnets on the back of the speakers would interfere with their operation. What I've done so far is made a shell out of fiberglass for the passenger door. I removed the stock panel and covered it with aluminum foil and duct tape. After 3 or 4 layers of fiberglass, I pulled the shell off, and began sanding. So now I'm trying to figure a way to get this to go back on. My panels use those push pins to keep them in place, but lining all that up with the fiberglass shell I made is going to be difficult. Also, I'm struggling with what to cover the panel with, and how to seal the window. Vinyl isn't forgiving enough, but cloth may look nice. Anybody got any helpful advice here? Oh and one more thing. I'm going to mount the 6.5" and the 4" in the panel, so how many layers do you suppose would be required to ensure maximum sturdiness? I've thrown down about 6 layers where the holes for the speakers are actually going, and like I said above, approximately 3 or 4 everywhere else. It seems pretty solid, but I've never worked with this stuff before.

My thanks in advance,

Pinch


Replies (1)
swez on 03/3/2004 12:38:09
Figure 3/8" thickness is good for where you mount your speakers. A little less is OK as these are not heavy or large speakers either.

As for aligment of the f/g panel to the door, consider installing temporary bolts with drywall anchors and paint the heads to get a transfer on the f/g as to where the push spike are to be located. You may need an extra pair of hands to do this properly. Then hot glue the spike in locations on the f/g for install.

As for covering, cloth makes sense but thin vinyl works too. Depending on interior covering used stock. As for water drip catcher, a sheet of thin neoprene should work. Just copy what stk door has now.

Can you see that as an option?

Swez





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